Method for producing turn-block pattern floor covering



March 18, 1958 v. SPENCER 2,827,

METHOD FOR PRODUCING TURN-BLOCK PATTERN FLOOR COVERING 5 Sheets-Sheet 1 Filed March 31, 1955 INVENTOR VIRGIL SPENCER ATTORNEY March 18, 1958 v. SPENCER METHOD FOR PRODUCING TURN-BLOCK PATTERN FLOOR COVERING 5 Sheets-Sheet 2 Filed March 31, 1955 INVENTOR VIRGIL SPENCER ATTORNEY United States Etenr W- METHOD FOR PRODUCING TURN-BLOCK PATTERN FLOOR COVERING Virgil Spencer, East Petersburg, Pa., assignor to Armstrong Cork Company, Lancaster, Pa., a corporation of Pennsylvania Application March 31, 1955, Serial No. 498,189

2 Claims. (Cl. 154-26) This invention relates to a floor covering and method and apparatus for producing the same. The method and apparatus here under consideration can be used in conjunction with conventional sheet-forming equipment to produce a floor covering design having pattern elements present therein without requiring the use of a continuous sheet of color composition six feet wide to form a very minor part of the final design. The method and apparatus of this invention can also be used in producing turn-block patterns on rotary equipment in which alternate blocks are turned at ninety degrees with respect to one another.

In the production of sheet material such as floor and wall covering of the linoleum type on conventional continuous sheet-forming equipment, it has been common practice to limit the number of different colored areas in the design to the number of cutting die rolls available on the machine. On standard machines four die rolls are utilized, limiting the design possibilities to four different colors of pattern elements in each design. In order to produce a final design having four differently colored pattern elements, it is necessary to supply a continuous sheet of material six feet wide to each die roll. The selected die roll cuts from the solid sheet the pattern elements of that particular color which are required in the final design. The balance of the sheet is returned for reprocessing, while the died out pattern elements are placed in their proper positions on the burlap or felt carrier passing through the machine. Each of the dies cuts from a differently colored sheet of material, and the collective pattern elements from the four dies form a complete design on the backing, covering the entire backing. All of the material not selected by the dies is returned for reprocessing. With this system, in order to produce a continuous sheet comprising four different color combinations, only 25% of the material going into the machine is utilized in the final product and the other 75% is rejected for reprocessing.

ro-m time to time efforts have been made to place blocks of difierent color or texture in the final design; and in order to do this, it was necessary to have the block cut to the exact shape and to have the dies so set up that an area of the backing was exposed in the exact size and shape of the cut block. This block is then inserted by hand. This was a rather diflicult task, and it was necessary to run the machine at very slow speeds in order to enable the operator to place the block in the props position.

In the manufacture of so-called turn-block patterns, in which alternate blocks are turned at ninety degrees with respect to one another, it has been common practice to supply a continuous sheet of jaspe or striated material to the rotary die. This rotary die cuts the sheet into blocks of whatever size is desired. In this case, the blocks are transferred from the die onto the backing. This died out material is then run over an inspection table and alternate blocks are turned by hand so as to produce a 2,827,103 Patented Mar. 18, 1958 turn-block pattern. Here again, the operation is slow because of the human element involved. Turn-block patterns have also been made by hand in which the backing is merely run over a table and operators place previously cut blocks in edge-to-edge relationship with one another, with the striated or jaspe lines running at ninety degrees with respect to the lines in the adjacent blocks.

In order to overcome the limitations of design set forth above and in order to develop a method in which turnblock patterns can be produced mechanically, the present invention has been developed. This invention involves the feeding of individual blankets to the rotary die, preferably in conjunction with at least one continuous sheet. It is conceivable, however, that an entire design could be made up by feeding individual blankets to rotary dies; however, in the preferred embodiment, one continuous sheet is fed to at least one rotary die and at least one rotary die is utilized in cutting design elements from individual blankets fed to the die in predetermined spaced relationship with one another. With this system, it is possible to greatly increase the possible color combinations and use only four rotary dies, which is the standard complement of dies for machines of this type. Three of the dies can be used on continuous sheets and the fourth die used to supply colors from blankets, or two dies can be used for continuous sheets and two dies for blankets, or one on a continuous sheet and three on blankets. In the case of turn-block patterns, it has been found that this can be carried on very satisfactorily by using one die on a continuous sheet and two dies on individual blankets.

An object of this invention is to provide a method of producing diedout floor and wall covering designs on the conventional four die rotary machine and increasing the number of color combinations beyond the number of dies used.

Another object of this invention is to produce turnblock patterns on a rotary machine without the necesity of turning alternate blocks by hand after they have been cut by the rotary die.

Another object of this invention is to provide a device for turning a sheet of jaspe material at right angles to the machine direction between the sheeting calender and the rotary die.

In order that this invention may be more readily understood, it will be described in connection with the attached drawings, in which:

Figure 1 shows a conventional turn-block pattern;

Figure 2 shows a turn-block pattern with a modified design element inserted in selected areas throughout;

Figure 3 shows the mechanism for carrying out the method by supplying a continuous sheet of material to one die and individual blankets to two dies;

Figure 4 shows a mechanism for turning the individual blankets before they are placed on the conveyor to be fed to the rotary die; and

Figure 5 shows a modified design producible by the method and on the apparatus covered by this application.

Referring to Figure 3, there is shown the assembly drum 2 of a conventional rotary continuous sheet-forming machine. Positioned around the periphery of the assembly drum 2 in spaced relationship are four die rolls 3A, 3B, 3C, and 3D. Positioned in engagement with each die roll is a back-up or cutting roll 4A, 4B, 4C, and 4D. The assembly drum 2 rotates in the direction of the arrow 5. In the particular embodiment shown in Figure 3, die roll 3A is not used in the production of the turn-block design here shown. Die roll 3B cuts blocks from a continuous sheet of striated material designated by the numeral 6, while die rolls 3C and 3D re supplied individual blankets 7 from two conveyors 8C and 8D. Each of the die rolls 3A, 3B, 3C, and 3D tions running inthe machine direction.

Figure l of the drawing.

has a cireumference of 54". Die roll 3B carries its complete complement of knives,twhile die rolls 3C and 3D have knives on only onehalf the circumference, or 27".

The individualrbl-ankets which areamade' with li16:iil'i3-:' tions running in'the machine direction are turned at ninety degrees with respect to the 'machine direction-before they are placed on the conveyors 8C and 8D. These} blankets may be previously cut and laid on the; con

veyors 8C and 8D;-by hand; or can be fed to tl' econveyor mechanically by the deviceof Fignred; to-be de' scribedlater. r t t It will be noted that the blankets onthej-conveyors 8C and 813 are spaced-in staggered relationshipg imother 3D by means of retainer pins which extend through the surface of the-die into the die ic'avity and penetrate k into the color blocks. These pins hold the blocks in engagement with the die roll and the blocks which are cut and do not form a part of the design are ejected from the die and fall onto a discharge conveyor 13, which conveys them to the start of the processing line. The die roll 3!), rotating in the direction of the arrow 9, transfers the selected cut color blocks from the point where the roll 3Dcuts in engagement with theroll 4D to the backing carried by the assembly drum 2. When the color blockscarried by the die roll engage the backing 10, they are stripped ofi the holding pins by means of a stripper mechanism actuated. angularly .outwardly by means of roller 11 mounted inside the die roll. Angular movement is imparted to'the rollers 11 by means of cams (not shown). When the blocks are stripped from the die cavity, -,they. are placed on and.

adhered to a tacky coating carried on the backing 10.

The above description is givenrin connection with a V nine-inch block pattern; however, it will be understood that the same invention can be utilized in making patterns with other size blocks by changing the dies and synchronizing the conveyors to function properly with difierent size blocks.

In order to supply the blankets 7 mechanically. to the j conveyors SC'and 8D, the mechanism shown in Figure 4 8D as well.

x uous rateof speed down a slide 16." The other half of The die'roll 3D-places three rows. of alternate color blocks across the entire width of the backing. The conveyor 8C carries blankets 7C to die roll SC in staggered relationship to the blankets supplied by conveyor 8D to die roll 3D. With this arrangement, the die roll 3C supplies its series of threealternate-rows of blocks to the backing, and these blocks are positioned immediately 7 adjacent to the blocks previously supplied by die roll 3D. It will be observed fiomPigure 3 that after the backing passes die roll 3C, it is uniformly covered with alternate blocks having their striations running in a direction at ninety degrees with respect to'the direction the material is traveling through the machine. These-blocks are designated by the numeral 12.

The backing carrying the alternate blocks 12 then passes under die roll 3B, whichl cuts blocks from the continuous sheet 6, which hastthe' jaspe lines or stria- Die' roll 33 difiers from die rolls3C and 3D in that'it'has' knives around its entire circumference, whereby-3C andSD have knives around only one-half their'circur'nference. Die

7 roll 3B cuts alternate blocks continuously frorn sheet 6 *and retains thedesired color blocks on the die in the same manner as was earlier explained for die rolls 3C and 3D.v The other. blocks are carried away on the return conveyor 13. As the backing leaves die r'oll 3C,

the entire design is formed with the blocks 12 having striations running at ninety degrees with respect to the "niachinedirection and the blocks 14' having striations The .pattei'n'or design shownbetween die rolls 3B and 3A on the assembly d'rum2' is-si'milar to that shown in This is illustrative of con ventional turn-block patterns. t t

the sheet is feddown a similar slide to the turning mech anism used in conjunctionwith conveyorSD; The con tinuous sheet 15 after it leaves the slide 16 passes around the continuously driven roller 17 operating at a constant conveyor 19 is moving intermittently, the conveyor 18- must move longitudinally to take up the slack in the web 15( This is accomplished by the roller 20 around which'conveyo'r 18 operates, carrying a sprocket 21 which is in engagement with the continuous constantly driven chain 22 driving pull r'ol1 '17. Sprocket 21 is also in engagement with the intermittently driving chain 23that 1 operates the. conveyor 19. This means that thesprocket 21 will always be rotatedjb'y 'chain22; but during'thatperiod of time that 23 is stationary, sprocket 21 merely rolls on chain. 23}, Wheii'chain'23 imparts the intermittentmotion to'conve'yorf19, it willcar'r'y sprocket 21- along with it and shorten the loopbetweentl'ie end of the slide and the end of the conveyor 191 With this arrangement, the belt'co'nveyor 18 on thefltop side is running at the same speed as the'web'15' while the belt.

' pose being to function as an automatic horizontal accumulator. 'in this manner, the web of material is always kept taut while being changed from'continuo'us motion to intermittent motion. i p

The conveyorbelt 19travels over, the driverolls 24 and 25, carrying with'it the web 15. The conveyor 19 goes around two forty-five degree tu'rnsticks designated at 26 and 27. The forty-five'degree' turnsticks-26and 27 turn the web of material 15 at ninety degrees with respect to its direction of entrance onto the conveyor 19.j

or 28. The web of material 15"continues along conveyor 28; whilethe conveyor 19 returns" around the roller 29, around middle turnstick 30, and back around the" drive roll 24. The'web 151continues face down in engagement with conveyor28 around drive roll 31 and onto a second reciprocating conveyor '32. Conveyor 32 is a rotating belt which is also moved reciprocally through V a'distance of seventy-two inches across the conVe'y r'SC. Positioned in the path of travel of the web 15 on the conveyor 32-is a cutting knife'33y which'severs thecon tinuous sheet 15 into individual blankets-(7C.

In the. drawing, one blanket 7C isbeing positioned oh theconveyor 80, while conveyor'32'is being withdrawm in a: direction away-from the' conveyor 80. As soon as the entire bIanket'7C is positioned on the'conveyor 86;.

the conveyor'32 moves. forward and then starts its with drawal while the next blanket 7C is depositedon-the tween the blankets is twenty-four inches so that when the overlap on the edge of the blanket is cut, the space between the die cut blocks will be exactly twenty-seven inches, and it is this twenty-seven inch space that is then supplied with blocks from conveyor 8D, that has a turning mechanism similar to that described.

The conveyors 19, 28, and 32 are built integrally on one frame to move forward synchronized with conveyor 8C during the laying of blanket 7C. At the same time as this above movement, the top side of the belt on conveyor 32 is not driven, and roll 34 is pulled back to deposit the blanket on conveyor 7C. The above two moves result in depositing blanket 7C onto conveyor 8C without a relative movement.

The remaining portion of this cycle is for the conveyor assembly on which are mounted conveyors 19, 23, and 32 to move away from the die, and during this same motion for conveyor roll 34 (without rotating) to be moved to the right to the point of beginning. This movement of conveyor 34 to the right feeds another six feet of Web 15 into position for laying.

During each cycle of reciprocation of the conveyor system, the cut-ofi knife 33 revolves at the proper time as synchronized with conveyor 32 to cut a seventy-eight inch blanket 7C from the continuous web. The blanket 7C is then in position to be laid on the conveyor 8C.

The blankets 7C are fed up the incline at the end of the conveyor 8C and into engagement wtih a belt conveyor 35, which carries the edge of the blanket in engagement with the back-up roll 4C into the nip of the die roll 3C. It is important that no slippage occurs at this point so that the blocks will be cut from the center of the blanket and do not extend out into the edge area of the blanket.

While the above description is directed to a mechanism which can be satisfactorily used for carrying out my invention, it will be understood that the blankets 7 may be laid on the conveyors by hand, with each conveyor 8C and 8D marked for the position of each blanket so that they will be fed in proper staggered relationship to the die rolls 3C and 3D to form the desired pattern efiect.

Figure 2 shows a modification of a turn-block design showing the blocks 12 and 14, the positioning of which has been explained earlier, but having certain blocks 36 that are not put in place by either of the die rolls 3B, 3C, or 3D. This can be done by utilizing the fourth die roll but having the area in which the blocks 36 are placed left blank by the die rolls 3B, 3C, and 3D. A conveyor similar to conveyor 80 or 8D is used in conjunction with die 3A. When the opening for block 36 is approaching die roll 3A, a small blanket slightly larger than the cavity of the block cut by die 4A is fed to the die, and the die cuts the single block in the same manner as is explained for dies 3C and 3D, cutting a plurality of blocks. This block is cut and the die roll places it in the opening and the finished design results. The blocks 36 may be of any color. The operator can supply a green one, a red one in the next instance, a yellow one in the next instance, and so on. The number of difierently colored blocks 36 is unlimited.

Figure 5 is an illustration of a design that can be produced utilizing this invention by slightly modifying the die arrangement to cut the design elements of the type shown therein.

The above description shows a method of utilizing my invention of supplying individual blankets to certain rotary dies in conjunction with continuous sheets supplied to other rotary dies to form unique pattern designs. It will be obvious to those skilled in the art that this invention greatly increases the possibility of pattern design on conventional pattern-forming machines. While the illustrations given herein are given in conjunction with square blocks, it will be understood that this invention could be carried out by utilizing blocks in any geometric configuration.

I claim:

1. In a method of producing floor and wall coverings having a continuous design composed of a plurality of pattern elements, the steps comprising passing a con tinuous web of backing material in close proximity to a plurality of rotatable die rolls provided with cutting knives defining die cavities, supplying individual sheets of color composition sequentially to certain of said die rolls in predetermined spaced relationship to one an other, dieing out pattern elements from substantially the entire area of said sheets during a portion only of each rotation of said die, retaining the died-out pattern elements in the cavity of said die and transferring said died-out pattern elements from said die to said backing material during each rotation of said die, supplying a continuous sheet of color composition from which pattern elements are to be died-out to one of said die rolls, dieing out pattern elements from said sheet continuously during the rotation of said die roll, and transferring certain died out pattern elements from the cavity of said die roll to the areas on the backing which have not been covered by the two previous dieing operations.

2. In a method of producing floor and Wall coverings having a continuous design composed of a plurality of pattern elements, the steps comprising passing a continuous web of backing material in close proximity to a plurality of rotatable die rolls provided with cutting knives defining die cavities, supplying individual sheets of color composition with the striations running at ninety degrees with respect to the machine direction of the material to certain of said die rolls in predetermined spaced relationship to one another, dieing out pattern elements from substantially the entire area of said sheets during a portion only of each rotation of said die roll, retaining certain died-out pattern elements in said die roll and transferring certain pattern elements from said die to the backing material, supplying a continuous sheet of color composition having striations running in the direction of travel of the sheet from which pattern elements are to be diedout to certain of said die rolls, dieing out pattern elements continuously from said striated sheets, retaining certain died-out pattern elements in said die, and transferring the retained pattern elements from said die to said backing material upon each rotation of the die in areas provided between adjacent previously positioned pattern elements.

References Cited in the file of this patent UNITED STATES PATENTS 264,972 Torrance Sept. 26, 1882 1,512,655 Van Amburgh Oct. 21, 1924 1,621,666 Guenther Mar. 22, 1927 1,860,242 Godfrey May 24, 1932 2,123,646 Campbell July 12, 1938 2,638,983 Ward May 19, 1953 2,654,415 Benedict et al. Oct. 6, 1953 

